电源线注塑流程.doc

工作指引Ref no: OI-ENG-006Title: Moulding 注塑 Rev: KDate: Dec 26,2006Page: 7 of 71.0 Title 标题1.1 Moulding 注塑2.0 Purpose目的2.1 This document defines the method for moulding. 该文件定义了注塑的方法3.0 Scope 范围3.1 This OI shall apply to all moulding processes within Volex Asia. 该OI适用于豪利士亚洲所有注塑工艺4.0 Reference 参考文件4.1 OP-ENG-009 Process Control 过程控制4.2 OP-QA-013 In process inspection 流程检查4.3 OP-PD-002-FM002 Route card 流程卡4.4 Production drawing 生产图纸4.5 Workmanship Standards 外观标准5.0 Definition 定义 5.1 OI: Operation Instruction 作业指引 5.2 IQC: In-coming Quality Control 来料品质控制 5.3 IPQC: In-process Quality Control 过程品质控制6.0 Equipment 设备6.1 Moulding machines 注塑机6.2 Mould 模具7.0 Safety Precaution 安全防范7.1 Safety covers must be in placed. 安全罩必须盖好7.2 Dual safety switch is operating, never operate when only single switch is able to operate the machine.双重安全开关必须正常方可操作,注塑机.仅单个安全开关绝不能操作7.3 The sensors are in place. 安全电眼应在适当位置 并正常工作8.0 Responsibilities and Authorities 职责和权限8.1 Only qualified operator shall operate the machine. Operator shall perform per paragraph 9.0. 只有培训合格的员工才可操作机器,操作员工须按照9.0进行8.2 Production supervisor / line leader shall ensure that the procedure is followed and route card is properly filled and attached.生产主管/拉长须保证操作员按程序操作,并完整填写流程单8.3 IPQC shall inspect per OP-QA-013. IPQC须依照OP-QA-013进行检查8.4 The technician shall be responsible for setting up the moulding machine. 技术员对注塑机的设置负责9.0Procedure 程序 9.1 Production drawing for the part to be processed must be available. 生产前,必须取得相应的生产图纸9.2 Before production WIP operator shall ensure, 生产前,WIP员工应确保, 9.2.1 PVC shall be prepared based on BOM. 根据BOM准备好胶料.9.2.2 Cut off the cotton thread knot with a suitable tool (e.g. scissor) before drawing out the cotton thread. The cotton thread must be cleaned out from the production line in time.拆开PVC袋之前用剪刀剪掉 棉线头,然后拉掉棉线,所有棉线必须及时从流程上清理干净.9.2.3 Check the inside of the PVC bag for any impurities before pouring the PVC into the plastic container. 检查PVC袋中是否有任何杂物,然后将PVC倒入胶料桶中. 9.2.4 Take IQC Passed label from the PVC bag and paste it on the plastic container.将PVC袋上的IQC Passed标签撕下贴在胶料桶上.9.3 The operator shall ensure route card is available and is properly filled by the previous operator.操作员必须确保挂有流程卡及已由上一工序操作员完整填写9.4 The operator shall check the production drawing to determine the direction of placement into the mould bar for moulding. Polarised blades and color orientation when specified in the production drawing must be correct.注塑时,操作员必须依生产图纸检查放入模把的极性端子及颜色方位，生产图纸上极性端子及颜色方位必须与生产 图纸的要求完全相符 1. Example of bridge mounted on mould bar. 2. Example of blade terminals mounted on mould bar. 1. 铜脚放入模把实例. 2.刀片端子放入模把实例All bridges, terminals are place in unilateral direction per orientation specified in the production drawing. 所有铜脚,端子应依照生产图纸要求的方位进行放置9.5 Terminated bridge, terminals shall fit nicely into the mould bars. 铜脚及端子必须准确插放入模把中9.6 The operator shall ensure that the mould cavity is free from any foreign particles before mounting the mould bar. The mould bar shall fit tightly into the bar slot. 模把放入前,操作员必须确保模腔内无异物.模把装入模把槽必须紧固.9.7 Dress the cables into the cable grip to prevent mould closure from cutting the cables.为防止闭模时损伤电线，将电线放入卡线槽并拉直Cables are dressed within the cable guides.电线在电线槽内9.8 Positioning of cable onto the grommet mould 电线在线套模里的位置9.8.1 For sample/ shuttler mould 样品模与手推模9.8.1.1 For short free end length, place the cable directly onto mould insert using edge of insert as reference.短线套,直接将电线放入如下图的线套模的沟槽里.9.8.1.2 For long free end length, place the free end on a measuring jig/ scale & place the cable on the mould. 长线套,将线套放入做好的工装夹具中并将电线放置在模具上.9.8.2 For production mould 生产模 9.8.2.1 For short free end length, place the cable directly on the mould bar.短线套,将电线直接放 进模把上.9.8.2.2 For long free end length, place the free end on a measuring jig/ scale & place the cable onto the mouldbar. Close the mould bar & load it onto the mould. 长线套,将自由端线套 放进夹具中,并将电线放进模把上,锁上模把并将其推进模具中. 9.8.3 If in order to meet special pull test, MEK must be sufficiently applied on cable surface as shown in the following method and photo prior to molding:为了满足特殊的拉力要求，在注塑前必须将MEK按下图所示的方法均匀地涂在电线上。9.8.3.1 Method 1: use a jig to help applying MEK on cable .方法1用工装将MEK涂在电线上。First fill MEK into the Jig. then place cable onto the jig and close the jig首先将MEK装入工装，然后将电线放入工装并合上工装 MEK have been applied on cable MEK已经涂在电线上了 9.8.3.2 Method 2: Use a brush to apply MEK on cable. First dip the brush on MEK container by pushing the cap down once or more times, then spread MEK on cable surface.方法2：用毛笔或刷子将MEK涂在电线上，首先将容器帽压下一次或多次，用毛笔或刷子蘸容器帽上的MEK，然后将MEK涂在电线表面。 Push the cap down with brush once or more times to pump up sufficient MEK on cap. 将容器帽压下一次或多次抽出容器内的MEK在帽上Use the brush to spread MEK to cable用毛笔将MEK涂在电线上MEK Container MEK容器 9.9 Activate the dual safety switch, ensuring that there is no contact between any other person and the mould pres启动安全开关,确保人和机器之间没有接触9.10 Allow the machine to close fully before releasing the fingers from the dual switch. Removing the fingers before the mould cycle is completed will de-activate the moulding process.机器完全闭模后，手脱离安全开关，一个注塑循环完成后,又重复此项操作9.11 After moulding, remove the plug or connector or strain relief from the mould bar without affecting the quality of the moulded product.注塑完后,将头插或尾插或网尾从模把中取出来,取出时,不能影响产品质量.9.12 There should be no impurities of color matter , non-permissible material to be incorporated into the moulded plug, connector and strain relief. 注塑时,确保头插或尾插或网尾没有杂物,无杂色进入. 9.13 The cable shall not be damaged by the mould closure. 注塑时,确保电线不被关闭模具所损伤 9.14 For plugs with fuse attachment, fuse shall be inserted after moulding. Examples of these plug types are as listed. 带有保险丝的插头,注塑后,再将保险丝装入插头.下面是带有保险丝插头的清单9.14.1 MP5004 (all range, eg. MP5004A, MP5004SC ) MP5004 (所有5004系列，例如： MP5004A, MP5004SC )9.14.2 MP5005 (all range eg. MP 5005SC ) MP5005 (所有5005系列，例如: MP 5005SC ) 9.15 Remove all runner from the mould and repeat the moulding process.从模具中取出水口料,重复注塑操作程序. 9.16 Refer to workmanship standards for inspection criteria 参考工艺标准 9.17 The operator shall fill the route card upon complete the process (Qty specified on the route card), especially on the IIR, and other details.操作员完成工位后应填写流程卡（应注明数量,进料检验报告及其他资料） 9.18 For plastics material, the pre-heat process must be monitor as following 塑胶料的预热流程按以下程序监督.9.18.1 For moulding machine with auto-loader